Modular fascia for refrigerator storage assemblies and methods of making same

ABSTRACT

A multi-component fascia assembly for refrigerator storage assemblies is provided. The fascia generally includes a face plate having a pair of end caps attached to the ends thereof. The fascia assembly can be attached to a support member to form a storage unit for a refrigerator. A refrigerator comprising a storage assembly having a multi-component fascia assembly also is provided. Additionally, a method of making a refrigerator storage assembly is provided and includes extruding an intermediate extrusion and cutting it to a predetermined length to form a face plate. The method also encompasses attaching end caps to the face plate to form a fascia which then can be attached to a support member to form a storage unit. One or more storage units can be formed and combined to create a refrigerator storage assembly.

TECHNICAL FIELD

The present invention generally relates to methods of forming storage assemblies and, more particularly, to methods of making modular fascia assemblies for refrigerators.

BACKGROUND

Over the years, household refrigerators have evolved to accommodate ever increasing functional demands by users. In addition to preserving food, refrigerators must be functionally versatile, easy to maintain and reasonably priced. Consumers desire refrigerators with adjustable storage compartments that can accommodate a variety of foods and food packagings and that are easily accessible to facilitate cleaning and maintenance. As a result, various manufacturers have offered refrigerators with removable shelves and storage assemblies.

Conventional refrigerators typically include various sized storage assemblies formed of injection molded polymeric components. In order to produce these various-sized storage assemblies, however, a manufacturer must construct a separate mold for each size of component. These molds typically are expensive, add to the cost of the final product, and increase the time required to bring a new product to market.

SUMMARY

The present invention generally is directed to modular or multi-component fascia assemblies for refrigerator storage assemblies, refrigerators containing multi-component fascia assemblies and methods of making the refrigerator storage assemblies. Multi-component fascia assemblies used in the refrigerator storage assemblies employ parts that can be used in multiple configurations, thereby potentially reducing the cost and time of manufacturing different fascia with different configurations.

In one embodiment, the present invention comprises a refrigerator having a cooling compartment formed of a top wall, a bottom wall, a rear wall, a first side wall, and a second side wall opposed to the first side wall. A storage assembly is disposed in the cooling compartment. The storage assembly includes a support member attached to a multi-component fascia, which is aligned distal to the rear wall within the cooling compartment. The multi-component fascia comprises a face plate having opposed ends and a pair of end caps attached to the opposed ends of the face plate.

In another embodiment, a fascia assembly for a refrigerator storage assembly includes a face plate having opposed ends and a channel formed therein. A pair of end caps are attached to opposite ends of said face plate. A second plate is disposed in the channel of the face plate and a cap is attached to each pair of end caps.

In a further embodiment, a method of making a refrigerator storage unit includes feeding a metal or polymeric material to an extruder and extruding the material through a die extruder to form an intermediate extrusion. The intermediate extrusion is cut to a predetermined length to form a face plate. The method can also include attaching a pair of end caps to the ends of the face plate to form a fascia assembly and attaching the fascia assembly to a support member to form a refrigerator storage unit.

In still another embodiment, a method of forming a refrigerator storage assembly includes feeding a material to an extruder and extruding the material through a die extruder to form a first intermediate extrusion. The first intermediate extrusion is cut to a first predetermined length to form a first face plate. The method can also include injection molding a first pair of end caps and attaching the first pair of end caps to the ends of the first face plate to form a first fascia. The method can additionally include attaching the first fascia to a first support member to form a first storage unit. Furthermore, a second intermediate extrusion is formed by extruding the material through the die. The second intermediate extrusion is cut to a second predetermined length to form a second face plate, with the first predetermined length being unequal to the second predetermined length. The method can also include attaching a second pair of end caps to the ends of the second face plate to form a second fascia and attaching the second fascia to a second support member to form a second storage unit. The first and the second storage units are mounted in a refrigerator cabinet to form a refrigerator storage assembly.

These and other aspects of the present invention are set forth in greater detail below and in the drawings, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a refrigerator containing a storage assembly with modular fascia assemblies.

FIG. 2 is a perspective view of the refrigerator of FIG. 1 with the top storage unit open and the ice shelf assembly removed.

FIG. 3 is a perspective view of the frame and fascia assembly of the top storage unit of the storage assembly shown in FIG. 2.

FIG. 4 is a perspective view of the top storage unit of FIG. 2 with the pans separated from the frame of the storage unit.

FIG. 5 is an exploded view of the bottom storage unit of FIG. 1.

FIG. 6 is a perspective view of a refrigerator containing a storage assembly that includes modular fascia assemblies.

FIG. 7 is a flowchart of a method of forming a fascia assembly.

FIG. 8 is a flowchart of an alternate method of forming a refrigerator storage assembly with modular fascia assemblies.

FIG. 9 is a flowchart of another method of forming a refrigerator storage assembly with modular fascia assemblies.

DETAILED DESCRIPTION

Referring now in more detail to FIGS. 1-9, in which like numerals refer where appropriate to like parts throughout the several views, FIG. 1 depicts a refrigerator 200 that contains a storage assembly 40 with multiple storage units 50 and 52 that include modular or multi-component fascia assemblies 70. The refrigerator 200 includes a cabinet 20 with an attached door 21. The cabinet 20 includes a top wall 24, a rear wall 22, a bottom wall 26, and first and second side walls 28 and 30. The walls of the cabinet 20 cooperate to define an insulated cooling compartment 32, which can be used for refrigerating and/or freezing food. Each of the storage units 50 and 52 includes a fascia assembly 70 that is disposed distal to the rear wall 22 of the cabinet 20 and facing outward. Some of the parts used to fabricate the fascia assemblies 70 of the storage units are interchanged and can be used on storage units of varying size, which can reduce the tooling and manufacturing costs of making variously configured storage units and assemblies for different refrigerator models.

The refrigerator storage assemblies 40 and 140 include various combinations of storage units 50, 52, and 250, each of which include a support member with a modular or multi-component fascia assembly 70 or 170 attached. The support members incorporated in the storage units can be shelves, drawers, bins, baskets, pans or similar structures for holding food in a refrigerator.

As shown in FIGS. 2-5, the fascia assembly 70 generally includes a face plate 72, a second plate 71, a cap 74 and a pair of end caps 76 a and 76 b. The face plate 72 includes a body having opposed ends and generally a uniform cross-section. A channel 84 (FIG. 5) is formed in the body of the face plate 72 for receiving second plate 71. The body of the face plate 72 also includes a front wall 80 and rear walls 81 and 82 that provide a large cross-section to add depth to the fascia assembly 70 and to provide more surface areas to engage the end caps 76 a and 76 b and other portions of the storage unit 50 and 52 as needed. However, the face plate 72 can be formed with a single wall or in other alternative configurations.

The second plate 71 is disposed in the channel 84 of the face plate 72 and extends between the ends caps 76 a and 76 b. The second plate 71 can be opaque, but is shown in the figures as translucent to provide visual access to the interior of the storage unit. The second plate 71 is shown as a single-walled body, but could comprise an alternative wall configuration.

The cap 74 is disposed over second plate 71 and extends between the end caps 76 a and 76 b. The cap 74 has a channel formed therein to receive the upper edge of the second plate 71. The cap 74 is attached to each of the pins of end caps 76 a and 76 b by one or more fasteners 73, which are shown in FIGS. 3-5 as screws.

Each of the end caps 76 a and 76 b includes an interior side, which is proximate one of the ends of the face plate 72, the second plate 71, and the cap 74. Each end cap 76 a and 76 b includes a face plate socket 78, a second plate socket 79, and a cap socket 75 formed on the interior side to receive the ends of the face plate 72, the second plate 71 and the cap 74, respectively.

When the fascia assembly 70 is assembled, the face plate 72 and the second plate 71 are attached to the end caps 76 a and 76 b by their engagement with the sockets of the end caps. The second plate 71 also is firmly secured in the fascia assembly 70 through alignment in the channel 84 of the face plate 72 and through engagement with the cap 74. Each end of the cap 74 extends through the cap sockets 75 of the end caps 76 a and 76 b. The cap 74 is secured to the end caps 76 a and 76 b by fasteners 73, shown as screws in the figures. Other types of fasteners, such as clips, pins, welds, or the like can be used to attach the components of the fascia assembly 70 together.

As shown in FIGS. 3-5, the fascia assemblies 70 are configured to be mounted or attached to support members 152 or 252 of the storage units 50 and 52. The support members 152 and 252 each include a frame 160 and 260, respectively, that are fastened to the fascia assemblies 70 by fasteners 77. The support members 152 and 252 alternatively can include pans 164 or a basket 66 to store food.

As shown in FIG. 6, refrigerator 300 includes a storage assembly 345 with various sized storage units 52 and 250. The size of the fascia assemblies 70 and 170 also vary according to the overall size of the storage units 52 and 250 to which the fascia are attached. Each left end cap 76a of storage units 52 and 250 are substantially identical to one another. Likewise, the right end caps 76 b are substantially identical to one another, even though the storage units 52 and 250 vary in width. Additionally, the face plates 72 and 172, the second plates 71 and 171, and the caps 74 and 174 are substantially similar, except in length between the wide storage unit 52 and the narrower storage units 250. Thus, at least some of the components of the fascia assemblies 70 and 170 can be interchanged or, with minor reconfiguration, can be used on dissimilarly sized storage units 52 and 250.

The present invention also is directed to methods of forming storage assemblies for refrigerators that include multi-component fascia assemblies. The methods generally include extruding a material through a die to form an intermediate extrusion that is cut to a predetermined length to form a face plate, a second plate, or cap. The extruded piece is attached to a support member, such as a shelf, drawer, bin, pan, basket, etc., to serve as at least a portion of the fascia of a storage unit. The use of extruded components to form the fascia assembly for a refrigerator storage unit facilitates production of storage units of various lengths using the same equipment while eliminating the requirement of obtaining a separate tooling mold for each sized unit, as required in molded components. The fascia assemblies formed by the methods detailed herein, however, can from assemblies that are substantially indistinguishable from assemblies constructed from molded parts.

FIGS. 7-9 show flowcharts of various methods of forming refrigerator storage assemblies. FIG. 7 shows a process for forming a refrigerator storage assembly beginning with feeding material to an extruder in step 100. The fed material preferably is a polymeric or metal material suitable for forming durable components. The polymeric materials can be selected from polyvinyl chlorides, polycarbonates, polyesters, chlorinated polyethylenes, acrylics, polystyrenes, acrylonitrile-butadiene-styrene copolymers, nylons, and any combinations or variations thereof. Additionally, metals, such as aluminum, copper or steel can be used in the method. The polymeric or metal material can be fed to the extruder in solid form, typically in the form of pellets, chips or billets.

The polymeric extruder includes a feed hopper connected to a barrel in which one or two conveyor screws are disposed. The screw(s) are rotated to carry the material toward a die. The material can be in a softened state by heat from the shearing actions of the screw(s) and/or by heat supplied to the barrel. The screw then forces or extrudes the material through the die in step 110. Extruding metal material includes placing a billet into equipment that heats the billet to a prescribed temperature. The heated metal then is pushed by a ram through the die. The opening in or formed by the die can have a variety of cross-sections depending upon the structure of the face plate to be formed. For example, the opening can have a cross-section like face plate 72, second plate 71 and/or cap 74 shown in FIG. 5.

The material solidifies and cools as it exits the die to form an intermediate extrusion in step 120. The intermediate extrusion has the desired cross-section, such as those shown in FIG. 5, or any other suitable cross-section, but also has an indeterminate length. The intermediate extrusion then is cut to a predetermined length in step 130. In one embodiment, simply cutting the intermediate extrusion to the predetermined length forms a face plate in step 140. In alternative embodiments, however, the step of forming the face plate 140 also can include bending, stamping, embossing, drilling, cutting, notching and other process steps, either singly or in combination, to form apertures, notches, tabs, grooves, channels, and other substructures within the extrusion. The face plate can be run through a coating process to form a specific finish, such as by painting the extrusion with a powder coating, or plating a material thereon.

The method also includes in step 150 attaching one or more end caps to the end(s) of the face plate. This step can include interlocking tabs, ribs, notches or other structures formed on the end caps and/or face plate, frictionally engaging the end caps to the face plate, or connecting them together with one or more fasteners, such as clips, screws, pins, adhesives or the like.

As shown in FIGS. 8 and 9, the methods detailed herein encompass forming two or more face plates of varying length with the same extruder and die. As with the process of FIG. 7, the method of FIG. 8 includes in step 100, feeding material to an extruder, extruding the material in step 110 through the die of the extruder, forming in step 120 an intermediate extrusion. In contrast to the method of FIG. 7, the method of claim 8 includes cutting the intermediate extrusion to a first predetermined length in step 230 and cutting an intermediate extrusion to a second predetermined length in step 330. The first predetermined length not being equal to the second predetermined length.

The first face plate is formed in step 240 from the portion of the intermediate extrusion cut to a first predetermined length, and the second face plate is formed in step 340 from the portion of the intermediate extrusion cut to the second predetermined length. As with the method of FIG. 7, steps 240 and 340 can include a variety of intermediate steps.

Other steps include attaching in step 250 a first pair of end caps to the ends of the first face plate and attaching in step 255 a second pair of end caps to the second face plate. These attachments can be formed by any variety of different processes detailed herein. These intermediate steps of forming and attachment can, but need not, be the same for the first and second face plates.

As shown in FIG. 9, the method can include in step 260 injection molding the first and second pairs of end caps. One or both pair of end caps can be identical or substantially similar to the other pairs of end caps, depending upon the desired form of the storage assemblies. The step 260 of injection molding the first and second pairs of end caps includes providing a mold of at least one of the end caps and injecting a material into the mold. The injected material is typically a polymeric material, such as polyvinyl chlorides, polycarbonates, polyesters, chlorinated polyethylenes, acrylics, polystyrenes, acrylonitrile-butadiene-styrene copolymers, nylons and any combinations or variations thereof. The end caps can be formed from one or more components. In one embodiment, two molds are provided corresponding to the two end caps that are to be attached to either end of the face plate. The end cap can be formed from a single mold and storage assemblies of varying length can include identical or substantially similar end caps.

Additionally, the method of FIG. 9 includes forming the first fascia 270 and the second fascia 360 and then attaching the first and second fascia to first and second support members 280 and 380, respectively. The first and second storage units can then be formed 290 and 390. In this manner, a refrigerator storage assembly containing a plurality of storage units can be made using parts formed from the same extruder or die.

Each of the methods of forming refrigerator storage assemblies described herein can include aligning a translucent, metal or polymeric second plate in a channel formed in the side wall of the face plate, in which the end-caps of the storage assembly engage the sides of the second plate. Additionally, the methods including this step can include an additional step of disposing a cap over the second plate. The cap can be engaged by the end caps of the assembly. Each of the methods can include the step of embossing the face plate to provide on the storage assembly one or more designs and/or indicia, such as the stylistic designs and company logos.

While the present invention has been described in detail herein in accord with certain embodiments, modifications can be made by those skilled in the art that fall within the scope of the invention. 

1. A refrigerator comprising: a cooling compartment comprising a top wall a bottom wall, a rear wall, a first side wall and a second side wall opposed to the first side wall; a storage assembly disposed in the cooling compartment, wherein the storage assembly comprises a support member and a multi-component fascia attached to the support member and aligned distal to the rear wall within the cooling compartment, wherein the multi-component fascia comprises a face plate having opposed ends and a pair of end caps attached to said opposed ends.
 2. The refrigerator of claim 1, wherein the face plate is formed of metal.
 3. The refrigerator of claim 1, wherein the multi-component fascia further comprises a translucent plate attached to said face plate.
 4. The refrigerator of claim 3, wherein the face plate includes a channel formed therein for receiving said translucent plate.
 5. The refrigerator of claim 1, wherein said multi-component fascia further comprises a cap attached to each of said pair of end caps.
 6. The refrigerator of claim 5, wherein said cap is formed of metal.
 7. The refrigerator of claim 5, wherein the multi-component fascia further comprises at least one fastener connecting said cap to at least one of said pair of end caps.
 8. The refrigerator of claim 1, wherein each of said pair of end caps is formed of a polymeric material.
 9. A fascia assembly for a refrigerator storage assembly comprising: a face plate having opposed ends and a channel formed therein; a pair of end caps attached to said opposed ends of said face plate; a second plate disposed in said channel of said face plate; and a cap attached to each of said pair of end caps.
 10. The fascia assembly of claim 9, wherein said face plate is formed of metal.
 11. The fascia assembly of claim 9, wherein said cap is formed of metal.
 12. The fascia assembly of claim 9, wherein said pair of end caps is formed of polymeric material.
 13. The fascia assembly of claim 9, wherein said second plate is translucent.
 14. A method of making a refrigerator storage unit comprising: feeding a material to an extruder, wherein the material is a metal or a polymeric material; extruding the material through a die of the extruder to form an intermediate extrusion; cutting the intermediate extrusion to a predetermined length to form a face plate; attaching a pair of end caps to the ends of the face plate to form a fascia assembly; and attaching the fascia assembly to a support member to form a refrigerator storage unit.
 15. The method of claim 14, wherein the pair of end caps are formed of a polymeric material by injection molding.
 16. The method of claim 14, further comprising: disposing a translucent plate between the pair of end caps.
 17. The method of claim 14, further comprising: extruding an intermediate cap extrusion.
 18. The method of claim 17, further comprising: cutting the intermediate cap extrusion to a predetermined length to form a cap.
 19. The method of claim 18, further comprising: attaching the cap to the pair of end caps.
 20. A method of forming a refrigerator storage assembly comprising: feeding a material to an extruder; extruding the material through a die of the extruder to form a first intermediate extrusion; cutting the first intermediate extrusion to a first predetermined length to form a first face plate; injection molding a first pair of end caps; attaching the first pair of end caps to the ends of the first face plate to form a first fascia; attaching the first fascia to a first support member to form a first storage unit; forming a second intermediate extrusion by extruding the material through the die; cutting the second intermediate extrusion to a second predetermined length to form a second face plate, wherein the first predetermined length is unequal to the second predetermined length; attaching a second pair of end caps to the ends of the second face plate to form a second fascia; attaching the second fascia to a second support member to form a second storage unit; and mounting the first and the second storage units in a refrigerator cabinet to form the refrigerator storage assembly.
 21. The method of claim 20, wherein the material is a polymeric composition selected from polyvinyl chlorides, polycarbonates, polyesters, chlorinated polyethylenes, acrylics, polystyrenes, acrylonitrile-butadiene-styrene copolymers, nylons and combinations thereof.
 22. The method of claim 20, wherein the material is a metal selected from aluminum, copper and steel.
 23. The method of claim 20, further comprising: aligning a translucent plate in a channel formed in the first face plate and engaging the ends of the translucent plate with the first pair of end caps.
 24. The method of claim 20, further comprising: disposing a cap over the translucent plate and engaging the ends of the cap with the first pair of end caps.
 25. The method of claim 20, wherein one of the first pair of end caps is substantially identical to one of the second pair of end caps. 